CN116348665A

CN116348665A - Heating system for diesel engine tail gas treatment liquid tank

Info

Publication number: CN116348665A
Application number: CN202180072475.XA
Authority: CN
Inventors: 肖恩·亚伦·罗基; 洛林·H·迈尔斯; 马修·理查德·哈德森; 凯尔·大卫·理查特; 科里·詹姆斯·弗莱彻; 丹尼尔·约瑟夫·莫茨
Original assignee: Cummins Power Co
Current assignee: Cummins Power Co
Priority date: 2020-10-23
Filing date: 2021-10-22
Publication date: 2023-06-27
Also published as: GB2615009A; GB202305594D0; WO2022087366A1; JP2023550686A; US11506100B2; DE112021004533T5; US20220127988A1

Abstract

The system and apparatus include a diesel exhaust fluid tank, a first temperature sensor positioned within the diesel exhaust fluid tank and configured to provide first temperature information indicative of a first temperature, and a second temperature sensor positioned within the diesel exhaust fluid tank and configured to provide second temperature information indicative of a second temperature. The system and apparatus also include one or more processing circuits including one or more memory devices coupled to the one or more processors, the one or more memory devices configured to store instructions thereon that, when executed by the one or more processors, cause the one or more processors to provide energy to the heating system based on the first temperature information and the second temperature information.

Description

Heating system for diesel engine tail gas treatment liquid tank

Cross Reference to Related Applications

The present application claims the benefit and priority of U.S. provisional patent application No. 63/104,848, filed on even 23 a 10/month 2020, the entire contents of which are incorporated herein by reference.

Technical Field

The present disclosure relates to engine exhaust aftertreatment systems. More specifically, the present disclosure relates to systems and methods for diesel exhaust fluid (diesel exhaust fluid, DEF) management in Selective Catalytic Reduction (SCR) aftertreatment systems.

Background

The SCR aftertreatment system consumes Diesel Exhaust Fluid (DEF). DEF typically comprises 32.5% urea and 67.5% deionized water. Typically, the DEF freezes at-12 degrees Celsius (-12 ℃) or 11 degrees Fahrenheit (11F.).

SUMMARY

One embodiment relates to a diesel exhaust fluid system comprising: the system includes a diesel exhaust fluid tank, a first temperature sensor positioned within the diesel exhaust fluid tank and configured to provide first temperature information indicative of a first temperature, a second temperature sensor positioned within the diesel exhaust fluid tank and configured to provide second temperature information indicative of a second temperature, and one or more processing circuits including one or more memory devices coupled to the one or more processors, the one or more memory devices configured to store instructions thereon that, when executed by the one or more processors, cause the one or more processors to provide energy to the heating system based on the first temperature information and the second temperature information.

Another embodiment relates to a diesel exhaust fluid tank control system for a diesel exhaust fluid tank including a temperature ultrasonic level and concentration (tunec) sensor and a heating system. The diesel exhaust fluid tank control system includes a temperature sensor array located within the diesel exhaust fluid tank and configured to provide temperature information, and one or more processing circuits including one or more memory devices coupled to one or more processors, the one or more memory devices configured to store instructions thereon that, when executed by the one or more processors, cause the one or more processors to provide energy to the heating system based on the temperature information.

Another embodiment relates to a method that includes receiving primary temperature information indicative of a primary temperature from a first temperature sensor located within a diesel exhaust fluid tank, receiving secondary temperature information indicative of a secondary temperature from a temperature sensor array located within the diesel exhaust fluid tank, and selectively powering a heating system located within the diesel exhaust fluid tank based on the primary temperature and the secondary temperature.

This summary is illustrative only and is not intended to be in any way limiting. Other aspects, inventive features, and advantages of the devices or processes described herein will become apparent in the detailed description set forth herein, considered in conjunction with the accompanying drawings, wherein like reference numerals designate like elements.

Brief Description of Drawings

Fig. 1 is a schematic diagram of a DEF heating system according to some embodiments.

Fig. 2 is a cross-sectional view of a DEF tank according to some embodiments.

Fig. 3 is a schematic diagram of a DEF heating system according to some embodiments.

Fig. 4 is a schematic diagram of a DEF heating system according to some embodiments.

Fig. 5 is a schematic diagram of a controller of a DEF heating system according to some embodiments.

Fig. 6 is a flow chart of a method for operating a DEF heating system, according to some embodiments.

Fig. 7A-7D are schematic diagrams of DEF heating systems according to some embodiments.

Fig. 8A-8D are schematic diagrams of DEF heating systems according to some embodiments.

Detailed Description

The following is a more detailed description of various concepts related to methods, apparatus, and systems for defrosting Diesel Exhaust Fluid (DEF) tanks, and implementations of these methods, apparatus, and systems. Before turning to the drawings, which illustrate certain exemplary embodiments in detail, it is to be understood that the disclosure is not limited to the details or methodology set forth in the specification or illustrated in the drawings. It is also to be understood that the terminology used herein is for the purpose of description only and should not be regarded as limiting.

Typical Diesel Exhaust Fluid (DEF) antifreeze systems utilize temperature ultrasonic level and concentration (tunec) sensors that include a single temperature sensor located within a DEF tank or vessel. The TULC sensor provides local defrosting performance because the temperature is measured only at a single location within the DEF tank and in some cases cannot indicate a uniform temperature of the DEF within the DEF tank as a whole. For example, off-highway vehicles (such as mining trucks) may have large engines (e.g., over 700 horsepower) and DEF tanks of greater than 30, 60, 100, and 200 gallons. In large DEF tanks, the local temperature measured by the tunec sensor is not always indicative of the DEF temperature in the entire DEF tank, especially at low temperatures (e.g., zero degrees fahrenheit). As previously described, DEF typically freezes at either 12 degrees celsius (-12 ℃) or 11 degrees fahrenheit (11°f) below zero.

In a typical system, a temperature signal from a TULC sensor is used to trigger a heat source applied to the DEF tank and other emission-related components. Accurate readings are important to ensure compliance with emissions requirements.

Referring generally to the figures, various embodiments disclosed herein relate to systems, devices, and methods for improving defrosting of DEF tanks. The DEF heating or thawing system includes a controller (e.g., an engine control module or a dedicated controller) that controls an electronically controlled coolant valve that selectively provides heated coolant from the engine to a heat exchanger located within the DEF tank to heat or thaw the DEF within the tank when the temperature of the DEF within the DEF tank is equal to or less than a predetermined temperature (e.g., 15 degrees celsius). The controller receives temperature information from a TULC sensor adjacent the heat exchanger and a secondary temperature sensor array comprising one or more temperature sensors spaced apart from the TULC sensor within the DEF tank. A secondary temperature sensor array in cooperation with the tunec sensor creates a temperature matrix for post-processing all temperature signals and provides a more accurate heating strategy and/or control of the DEF heating system. A preprogrammed model, algorithm, logic, or machine learning scheme may be used to create a temperature matrix to provide a more accurate thermal model of the DEF within the DEF tank and thus provide more accurate control of the electronically controlled coolant valve to more successfully maintain the temperature within the DEF tank or defrost the DEF. The improved DEF heating system provides advantages including the elimination of hot spots near the TULC sensor that would cause the coolant flow to the heat exchanger to shut off prematurely, allowing some of the DEF within the DEF tank to remain frozen. Another advantage of a more accurate thermal model is that false indications of the amount of thawed DEF ready for injection are eliminated. The thermal model allows the aftertreatment system to successfully begin dosing faster.

As shown in fig. 1, a diesel exhaust fluid system in the form of a DEF heating system 10 includes an engine 14, a DEF tank 18, and a switching element in the form of an electronically controlled coolant valve 22 that controls the flow of energy to the DEF tank 18 to heat the DEF held within the DEF tank 18. In some embodiments, the switching element comprises an electronic switch, a mechanically operated valve, or other switching device. In some embodiments, the energy to heat the DEF tank 18 is provided by a generator, a battery, an auxiliary heating system, or another heat source other than the engine 14. Typically, the engine 14 generates heat that is absorbed by the coolant. An electronically controlled coolant valve 22 controls coolant flow to the DEF tank 18 to heat the DEF tank.

As shown in fig. 2, the DEF tank 18 includes a header 26, the header 26 being configured to seal the DEF tank 18 and support a filter, suction and fill tubes for DEF, and a heating unit 30, the heating unit 30 including a heating element in the form of a heat exchanger 34 and a tunec sensor 38. In some embodiments, the heating element is a submersible resistive heating element or another heating element, as desired. The header 26 includes two substantially identical heating units 30, 30'. In some embodiments, more or less than two heating units 30 are included in the header 26. The heat exchanger 34 is fluidly coupled to the electronically controlled coolant valve 22 and selectively receives coolant heated by the engine 14. The heat exchanger 34 exchanges heat between the DEF held in the DEF tank 18 and the coolant heated by the engine 14.

As shown in fig. 3, the tunec sensor 38 is located in the center of the DEF tank 18. The DEF heating system 10 further comprises a secondary sensor array 42, the secondary sensor array 42 comprising a first temperature sensor 46, a second temperature sensor 50, a third temperature sensor 54 and a fourth temperature sensor 58. In some embodiments, the TULC sensor 38 comprises a sensor package comprising a liquid level sensor, a mass sensor, and a first temperature sensor. In some embodiments, the secondary sensor array 42 includes more than four temperature sensors or less than four temperature sensors. For example, in a 30 gallon DEF tank, one temperature sensor within the secondary sensor array 42 may be sufficient, while a 100 gallon DEF tank may require five temperature sensors within the secondary sensor array 42. The secondary sensor array 42 is positioned to sense the temperature of the DEF within the DEF tank 18 at a location remote from the TULC sensor 38. For example, corners of a large DEF tank 18 may receive less thermal cycling and therefore may not heat uniformly with the majority of the DEF within the DEF tank 18. The secondary sensor array 42 may position temperature sensors in remote corners to provide temperature in the corners. As shown in fig. 3, four

temperature sensors

46, 50, 54, 58 are located at the four corners of the generally rectangular-shaped DEF tank 18.

The TULC sensor 38 is communicatively coupled to an Engine Control Module (ECM) 62 associated with the engine 14. The secondary sensor array 42 is coupled to a diesel exhaust fluid tank control system in the form of a controller 66, which controller 66 communicates with the ECM 62. In some embodiments, the controller 66 is mounted on the engine 14. In some embodiments, the controller 66 is mounted remotely from the engine 14. The ECM 62 and the controller 66 cooperate and develop a thermal model of the DEF tank 18. In some embodiments, the controller 66 is embodied as a module or circuit within the ECM 62. In some embodiments, controller 66 is a separate controller located remotely from ECM 62. In some embodiments, aspects of ECM 62 and controller 66 are shared, distributed, or combined in a cloud-based control scheme.

As shown in FIG. 4, the TULC sensor 38 and the secondary sensor array 42 may be in direct communication with the controller 66, and the controller 66 may be in communication with the ECM 62 to effect control of the electronically controlled coolant valve 22. In some embodiments, the controller 66 communicates directly with the electronically controlled coolant valve 22 without intervention of the ECM 62.

Since the components of fig. 1 are shown as being embodied in a vehicle that includes the DEF heating system 10, the controller 66 may be configured as one or more Electronic Control Units (ECUs). The controller 66 may be separate from or included in at least one of a transmission control unit, an exhaust aftertreatment control unit, a powertrain control module, an engine control module (e.g., the ECM 62), and the like. The function and structure of the controller 66 is described in more detail in fig. 5.

Referring now to fig. 5, a schematic diagram of the controller 66 of the DEF heating system 10 of fig. 1 is shown, according to an example embodiment. As shown in fig. 5, the controller 66 includes: the processing circuit 70 having the processor 74 and the memory device 78, the control system 80 having the sensor circuit 84, the ECM circuit 88, the modeling engine 92, and the heating circuit 96, and the communication interface 100. In general, the controller 66 is configured to generate a thermal model of the DEF tank 18 and control operation of the electronically controlled coolant valve 22.

In one configuration, the sensor circuit 84, ECM circuit 88, modeling engine 92, and heating circuit 96 are embodied as machine or computer readable media executable by a processor, such as the processor 74. As described herein and in other applications, a machine-readable medium facilitates performing certain operations to enable the reception and transmission of data. For example, a machine-readable medium may provide instructions (e.g., commands, etc.) to, for example, collect data. In this regard, a machine readable medium may include programmable logic defining a data acquisition (or data transmission) frequency. The computer readable medium may include code that may be written in any programming language, including, but not limited to, java or the like and any conventional procedural programming language, such as the "C" programming language or similar programming languages. The computer readable program code may be executed on a processor or multiple remote processors. In the latter case, the remote processors may be interconnected by any type of network (e.g., CAN bus, etc.).

In another configuration, the sensor circuit 84, ECM circuit 88, modeling engine 92, and heating circuit 96 are embodied as hardware units, such as an electronic control unit. Accordingly, the sensor circuit 84, ECM circuit 88, modeling engine 92, and heating circuit 96 may be embodied as one or more circuit components including, but not limited to, processing circuits, network interfaces, peripherals, input devices, output devices, sensors, and the like. In some embodiments, the sensor circuit 84, ECM circuit 88, modeling engine 92, and heating circuit 96 may take the form of one or more analog circuits, electronic circuits (e.g., integrated Circuits (ICs), discrete circuits, system-on-a-chip (SOC) circuits, microcontrollers, etc.), telecommunications circuits, hybrid circuits, and any other type of "circuit. In this regard, the sensor circuit 84, ECM circuit 88, modeling engine 92, and heating circuit 96 may include any type of components for accomplishing or facilitating the operations described herein. For example, the circuits described herein may include one OR more transistors, logic gates (e.g., NAND, AND, NOR, OR, exclusive OR (XOR), NOT (NOT), exclusive NOR (XNOR), etc.), resistors, multiplexers, registers, capacitors, inductors, diodes, wiring, AND so forth. The sensor circuit 84, ECM circuit 88, modeling engine 92, and heating circuit 96 may also include programmable hardware devices such as field programmable gate arrays, programmable array logic, programmable logic devices, and the like. The sensor circuit 84, ECM circuit 88, modeling engine 92, and heating circuit 96 may include one or more memory devices for storing instructions executable by the processors of the sensor circuit 84, ECM circuit 88, modeling engine 92, and heating circuit 96. One or more memory devices and processors may have the same definition as provided below with respect to memory device 78 and processor 74. In some hardware unit configurations, the sensor circuit 84, ECM circuit 88, modeling engine 92, and heating circuit 96 may be geographically dispersed at separate locations in the vehicle. Alternatively, and as shown, the sensor circuit 84, ECM circuit 88, modeling engine 92, and heating circuit 96 may be embodied in or within a single unit/housing, which is shown as the controller 66.

In the example shown, the controller 66 includes a processing circuit 70 having a processor 74 and a memory device 78. The processing circuitry 70 may be constructed or configured to perform or implement the instructions, commands, and/or control processes described herein with respect to the sensor circuitry 84, ECM circuitry 88, modeling engine 92, and heating circuitry 96. The depicted configuration represents the sensor circuit 84, ECM circuit 88, modeling engine 92, and heating circuit 96 as machine or computer readable media. However, as noted above, this illustration is not meant to be limiting, as the present disclosure contemplates other embodiments in which the sensor circuit 84, ECM circuit 88, modeling engine 92, and heating circuit 96, or at least one of the sensor circuit 84, ECM circuit 88, modeling engine 92, and heating circuit 96, is configured as a hardware unit. All such combinations and modifications are intended to be within the scope of the present disclosure.

The hardware and data processing components (e.g., processor 74) used to implement the various processes, operations, illustrative logic, logic blocks, modules, and circuits described in connection with the embodiments disclosed herein may be implemented or performed with a general purpose single or multi-chip processor, a Digital Signal Processor (DSP), an Application Specific Integrated Circuit (ASIC), a Field Programmable Gate Array (FPGA) or other programmable logic device, discrete gate or transistor logic, discrete hardware components, or any combination thereof designed to perform the functions described herein. A general purpose processor may be a microprocessor or any conventional processor or state machine. A processor may also be implemented as a combination of computing devices, such as a combination of a DSP and a microprocessor, a plurality of microprocessors, one or more microprocessors in conjunction with a DSP core, or any other such configuration. In some embodiments, one or more processors may be shared by multiple circuits (e.g., sensor circuit 84, ECM circuit 88, modeling engine 92, and heating circuit 96 may include or otherwise share the same processor, which in some example embodiments may execute instructions stored or otherwise accessed via different areas of memory). Alternatively or additionally, one or more processors may be configured to perform or otherwise perform certain operations independently of one or more coprocessors. In other example embodiments, two or more processors may be coupled via a bus to enable independent, parallel, pipelined, or multi-threaded instruction execution. All such variations are intended to fall within the scope of the present disclosure.

The memory device 78 (e.g., memory unit, storage device) may include one or more devices (e.g., RAM, ROM, flash memory, hard disk storage) for storing data and/or computer code to complete or facilitate the various processes, layers, and modules described in this disclosure. The memory device 78 may be communicatively connected to the processor 74 to provide computer code or instructions to the processor 74 for performing at least some of the processes described herein. Further, the memory device 78 may be or include tangible, non-transitory, volatile memory or non-volatile memory. Accordingly, memory device 78 may include database components, object code components, script components, or any other type of information structure for supporting the various activities and information structures described herein.

Sensor circuit 84 is configured to collect temperature information from the TULC sensor 38 and the secondary sensor array 42 via communication interface 100. In some embodiments, sensor circuit 84 manipulates information provided by TULC sensor 38 and secondary sensor array 42 for use by controller 66. For example, the sensor circuit 84 may average the temperature information of the various sensors (e.g.,

temperature sensors

46, 50, 54, 58), process them with a weighted average, or perform other processing.

The ECM circuit 88 is configured to communicate with the ECM 62 to coordinate actions therewith. In some embodiments, the ECM circuit 88 is the ECM 62. In some embodiments, the ECM circuit 88 controls operation of the electronically controlled coolant valve 22 by providing communication with the ECM 62 via the communication interface 100. In some embodiments, the sensor circuit 84 is not in direct communication with the TULC sensor 38, and temperature information from the TULC sensor 38 is received by the ECM circuit 88.

The modeling engine 92 is configured to generate a thermal model of the DEF tank 18 based on temperature information received from the sensor circuit 84 and the ECM circuit 88. In some embodiments, the thermal model includes a machine learning scheme (reinforcement learning, neural network, etc.) that learns the relationship between the TULC sensor 38 and the secondary sensor array to generate a three-dimensional heat map of the DEF tank 18 and to determine locations in the DEF tank 18 where the DEF is above a predetermined threshold temperature and locations in the DEF tank 18 where the DEF is below the threshold temperature. In some embodiments, the thermal model is based on a preprogrammed model, algorithm, ladder logic, and the like.

In some embodiments, the temperature indicated by the TULC sensor 38 is a primary temperature T1 and the temperature indicated by the secondary sensor array 42 is a secondary temperature T2. In some embodiments, each individual sensor in secondary sensor array 42 is assigned a temperature (e.g., T2-T5). The modeling engine 92 then compares the primary temperature T1 to the secondary temperature T2 or all of the secondary temperatures T2-T5 and returns the lowest temperature for use by the controller 66. For example, if the secondary temperature T2 is less than the primary temperature T1, the thermal model returns to the secondary temperature. In some embodiments, temperatures T1-T5 are assigned a weighted average such that sensors are given priority. For example, the main temperature T1 determined by the TULC sensor 38 may be the highest priority temperature. The modeling engine 92 may specify a predetermined range in which to return the main temperature. For example, if the threshold temperature is 15 degrees celsius (15 ℃) and the range is 1 degree celsius (1 ℃), the secondary temperature will return when the secondary temperature is equal to or less than 14 degrees celsius (14 ℃).

The heating circuit 96 receives the thermal model and communicates with the electronically controlled coolant valve 22 to actuate the electronically controlled coolant valve 22 between an open position in which coolant is provided to the heat exchanger 34 and a closed position in which coolant is inhibited from flowing to the heat exchanger 34. In some embodiments, the electronically controlled coolant valve 22 is closed when the thermal model indicates that the temperature of the DEF within the DEF tank 18 is equal to or above a threshold temperature (e.g., 15 ℃) and the electronically controlled coolant valve 22 is open when the thermal model indicates that the temperature of the DEF within the DEF tank 18 is below the threshold temperature (e.g., 15 ℃). In some embodiments, the heating circuit 96 communicates with the ECM 62 via a communication interface 100 to implement control of the electronically controlled coolant valve 22.

As shown in fig. 6, the method 104 of operating the DEF heating system 10 includes receiving a primary temperature T1 from the TULC sensor 38 at step 108 and receiving a secondary temperature T2 from the secondary sensor array 42 at step 112. Controller 66 then generates a thermal model at step 116. In some embodiments, the thermal model generated at step 116 is directly used (e.g., via a three-dimensional heat map) to determine parameters of the DEF (e.g., percentage and distribution of the melted DEF, volume of the melted DEF, temperature distribution, etc.) and the thermal model is directly used to determine operation of the electronically controlled coolant valve 22.

As shown in fig. 6, controller 66 compares the primary temperature to the secondary temperature at step 120. If the primary temperature T1 is less than or equal to the secondary temperature T2, the method 104 proceeds to step 124 and compares the primary temperature T1 to a threshold temperature (e.g., 15 ℃). If the main temperature T1 is less than (or equal to) the threshold temperature, the Diesel Exhaust Fluid (DEF) pump cannot yet be started and the DEF tank 18 must be thawed. At step 128, the electronically controlled coolant valve 22 is opened to heat the DEF within the DEF tank 18, and the method returns to

steps

108 and 112. If the primary temperature T1 is greater than (or equal to) the threshold temperature at step 124, the method 104 proceeds to step 132 and the controller 66 compares the secondary temperature T2 to the threshold temperature. If the secondary temperature T2 is greater than (or equal to) the threshold temperature, the DEF pump is started at step 136. If the secondary temperature T2 is less than (or equal to) the threshold temperature at step 132, the electronically controlled coolant valve 22 is opened and the DEF is further heated. In some embodiments, step 132 is eliminated.

If the secondary temperature T2 is less than the primary temperature T1 at step 120, the method 104 proceeds to step 140 and compares the secondary temperature T2 to a threshold temperature. If the secondary temperature T2 is less than (or equal to) the threshold temperature, the electronically controlled coolant valve 22 is opened at step 128, and if the secondary temperature T2 is greater than (or equal to) the threshold temperature, the DEF pump is started at step 136.

The above-described systems and methods advantageously provide improved control of DEF thawing and heating within large DEF tanks. This is particularly important, for example, in the following situations: the DEF tank 18 is greater than 30 gallons and where existing systems falsely indicate the DEF temperature in the entire DEF tank 18, there is often a cold spot.

As shown in fig. 7A-7D, the DEF tank 18 comprising the first heating unit 30 and the second heating unit 30 'may be arranged in opposite directions, with the

secondary sensors

46 and 50 arranged spaced apart from the heat exchangers 34 and 34'. The location of the TULC 38 is generally centered within the DEF tank 18 to reduce the effects of sloshing of the DEF within the DEF tank 18. However, without the addition of the secondary sensor array 42 including the

secondary sensors

46 and 50, the center position of the TULC 38 may result in inaccurate assessment of the DEF status within the DEF tank 18. Fig. 8A-8D illustrate another embodiment of the DEF tank 18, the DEF tank 18 comprising two heating units 30 and 30' arranged substantially parallel facing in the same direction. In some embodiments, the DEF tank arrangement shown in fig. 7A-7D and fig. 8A-8D may include only one secondary sensor 46 or more than two secondary sensors. The heat exchangers 34, 34' are located in separate portions of the DEF tank 18 to provide heating to separate areas, volumes, or portions of the DEF tank 18 to more uniformly defrost the DEF within the DEF tank 18. The separate portions of the DEF tank 18 do not overlap. The heat exchangers 34, 34' are arranged in a non-overlapping manner in the separation section. In some embodiments, a first heating element comprising a heat exchanger 34 is positioned in a first portion of the diesel exhaust fluid tank 18, and a second heating element comprising a heat exchanger 34' is positioned in a second portion of the diesel exhaust fluid tank 18 that does not overlap the first portion.

As used herein, the terms "about," "substantially," and similar terms are intended to have a broad meaning consistent with common and acceptable usage by those of ordinary skill in the art to which the presently disclosed subject matter pertains. Those skilled in the art having the benefit of this disclosure will appreciate that these terms are intended to allow the description of certain features described and claimed without limiting the scope of such features to the precise numerical ranges provided. Accordingly, these terms should be construed to indicate that insubstantial or insignificant modifications or variations to the described and claimed subject matter are considered to be within the scope of the disclosure set forth in the appended claims.

It should be noted that the term "exemplary" and variations thereof as used herein to describe various embodiments are intended to indicate that these embodiments are possible examples, representations, and/or illustrations of possible embodiments (and such term is not intended to imply that such embodiments are necessarily very or the highest level of examples).

The term "coupled" and variants thereof as used herein mean that two members are directly or indirectly coupled to each other. Such coupling may be fixed (e.g., permanent or unchanged) or movable (e.g., removable or releasable). Such coupling may be achieved by the two members being directly coupled to each other, by the two members being coupled to each other using one or more separate intermediate members, or by the two members being coupled to each other using an intermediate member integrally formed as a single unitary body with one of the two members. If "coupled" or variations thereof is modified by additional terminology (e.g., directly coupled), the generic definition of "coupled" provided above is modified by the plain language meaning of the additional terminology (e.g., "directly coupled" meaning the joining of two members without any separate intermediate member), resulting in a narrower definition than the generic definition of "coupled" provided above. This coupling may be mechanical, electrical or fluid. For example, circuit a being communicatively "coupled" to circuit B may mean that circuit a communicates directly with circuit B (i.e., without intermediaries) or indirectly with circuit B (e.g., through one or more intermediaries).

References herein to the location of elements (e.g., "top," "bottom," "above," "below") are merely used to describe the orientation of the various elements in the drawings. It should be noted that the orientation of the various elements may be different according to other exemplary embodiments, and such variations are intended to be included in the present disclosure.

Although various circuits having particular functions are shown in fig. 5, it should be understood that controller 66 may include any number of circuits for accomplishing the functions described herein. For example, the activities and functions of the sensor circuit 84, ECM circuit 88, modeling engine 92, and heating circuit 96 may be combined into multiple circuits or a single circuit. Additional circuitry with additional functionality may also be included. In addition, the controller 66 may further control other activities beyond the scope of the present disclosure.

As described above and in one configuration, the "circuitry" may be implemented in a machine-readable medium for execution by various types of processors, such as processor 74 of FIG. 5. The identification circuitry of executable code may, for example, comprise one or more physical or logical blocks of computer instructions which may, for example, be organized as an object, procedure, or function. However, the executables of an identified circuit need not be physically located together, but may comprise disparate instructions stored in different locations which, when joined logically together, comprise the circuit and achieve the stated purpose for the circuit. Indeed, the circuitry of the computer readable program code may be a single instruction, or many instructions, and may even be distributed over several different code segments, among different programs, and across several memory devices. Similarly, operational data may be identified and illustrated herein within circuits, and may be embodied in any suitable form and organized within any suitable type of data structure. The operational data may be collected as a single data set, or may be distributed over different locations including over different storage devices.

Although the term "processor" is briefly defined above, the terms "processor" and "processing circuitry" are intended to be interpreted broadly. In this regard and as described above, a "processor" may be implemented as one or more general purpose processors, application Specific Integrated Circuits (ASICs), field Programmable Gate Arrays (FPGAs), digital Signal Processors (DSPs), or other suitable electronic data processing components configured to execute instructions provided by a memory. One or more processors may take the form of a single-core processor, a multi-core processor (e.g., dual-core processor, tri-core processor, quad-core processor, etc.), a microprocessor, or the like. In some embodiments, one or more processors may be external to the apparatus, e.g., one or more processors may be remote processors (e.g., cloud-based processors). Alternatively or additionally, one or more processors may be internal to the device and/or local. In this regard, a given circuit or component thereof may be located locally (e.g., as part of a local server, local computing system, etc.) or remotely (e.g., as part of a remote server such as a cloud-based server). To this end, a "circuit" as described herein may include components distributed over one or more locations.

Embodiments within the scope of the present disclosure include program products comprising machine-readable media for carrying or having machine-executable instructions or data structures stored thereon. Such machine-readable media can be any available media that can be accessed by a general purpose or special purpose computer or other machine with a processor. Such machine-readable media may include, for example, RAM, ROM, EPROM, EEPROM or other optical disk storage, magnetic disk storage or other magnetic storage devices, or any other medium that may be used to carry or store desired program code in the form of machine-executable instructions or data structures and that may be accessed by a general purpose or special purpose computer or other machine with a processor. Combinations of the above are also included within the scope of machine-readable media. Machine-executable instructions comprise, for example, instructions and data which cause a general purpose computer, special purpose computer, or special purpose processing machine to perform a certain function or group of functions.

Although the figures and descriptions may show a particular order of method steps, the order of the steps may differ from what is depicted and described, unless otherwise specified above. Furthermore, two or more steps may be performed concurrently or with partial concurrence, unless stated differently above. Such variations may depend, for example, on the software and hardware system selected and the designer's choice. All such variations are within the scope of the present disclosure. Likewise, software implementations of the described methods may be accomplished with standard programming techniques with rule based logic and other logic to accomplish the various connection steps, processing steps, comparison steps and decision steps.

It is important to note that the construction and arrangement of the DEF heating system 10 as shown in the various exemplary embodiments is illustrative only. Additionally, any element disclosed in one embodiment may be combined with or used in conjunction with any other embodiment disclosed herein. For example, the controller 66 of the exemplary embodiment may be incorporated into the ECM 62 of the exemplary embodiment. Although only one example of an element from one embodiment that can be combined or used in another embodiment is described above, it should be understood that other elements of various embodiments can be combined or used with any of the other embodiments disclosed herein.

Claims

1. A diesel exhaust fluid system comprising:

a diesel engine tail gas treatment liquid tank;

a first temperature sensor positioned within the diesel exhaust fluid tank and configured to provide first temperature information indicative of a first temperature;

a second temperature sensor positioned within the diesel exhaust fluid tank and configured to provide second temperature information indicative of a second temperature; and

one or more processing circuits including one or more memory devices coupled to one or more processors, the one or more memory devices configured to store instructions thereon that, when executed by the one or more processors, cause the one or more processors to provide energy to a heating system based on the first temperature information and the second temperature information.

2. The diesel exhaust fluid system of claim 1, wherein the one or more processing circuits further comprise an engine control module configured to receive the first temperature information.

3. The diesel exhaust fluid system of claim 1, wherein the one or more memory devices are further configured to store instructions thereon that, when executed by the one or more processors, cause the one or more processors to generate a thermal model of the diesel exhaust fluid tank, and

wherein energy is provided to the heating system when the thermal model indicates that diesel exhaust fluid within the diesel exhaust fluid tank is greater than or equal to a predetermined threshold.

4. The diesel exhaust fluid system of claim 1, wherein the one or more memory devices are further configured to store instructions thereon that, when executed by the one or more processors, cause the one or more processors to:

providing energy to a heating element when (i) the first temperature is greater than or equal to a predetermined threshold and the second temperature is within a predetermined range from the first temperature, or (ii) the second temperature is greater than or equal to the predetermined threshold and the second temperature is not within the predetermined range from the first temperature.

5. The diesel exhaust fluid system of claim 1, wherein the diesel exhaust fluid tank is equal to or greater than 30 gallons.

6. The diesel exhaust fluid system of claim 1, further comprising an exhaust fluid tank header,

wherein the exhaust treatment fluid tank header supports each of the heating system, the first temperature sensor, and the second temperature sensor.

7. The diesel exhaust fluid system of claim 1, further comprising a sensor package including a liquid level sensor, a mass sensor, and the first temperature sensor.

8. The diesel exhaust fluid system of claim 7, further comprising:

a third temperature sensor positioned within the diesel exhaust fluid tank and configured to provide third temperature information indicative of a third temperature;

a fourth temperature sensor positioned within the diesel exhaust fluid tank and configured to provide fourth temperature information indicative of a fourth temperature; and

a fifth temperature sensor is positioned within the diesel exhaust fluid tank and is configured to provide fifth temperature information indicative of a fifth temperature.

9. The diesel exhaust fluid system of claim 8, wherein the one or more processing circuits further comprise an engine control module configured to receive the first temperature information from a combination sensor, and

wherein the one or more memory devices are further configured to store instructions thereon that, when executed by the one or more processors, cause the one or more processors to:

receiving the first temperature information from the engine control module;

receiving the second temperature information from the second temperature sensor;

receiving the third temperature information from the third temperature sensor;

receiving the fourth temperature information from the fourth temperature sensor;

receiving the fifth temperature information from the fifth temperature sensor; and

and generating a thermal model of the diesel exhaust fluid tank based on the first temperature information, the second temperature information, the third temperature information, the fourth temperature information and the fifth temperature information.

10. The diesel exhaust fluid system of claim 1, further comprising the heating system, wherein the heating system comprises a heating element.

11. The diesel exhaust fluid system of claim 10, wherein the heating element comprises a heat exchanger configured to receive coolant from an engine.

12. The diesel exhaust fluid system of claim 1, further comprising the heating system,

wherein the heating system comprises

A first heating element located in a first portion of the diesel exhaust fluid tank, an

A second heating element located in a second portion of the diesel exhaust fluid tank that does not overlap the first portion.

13. The diesel exhaust fluid system of claim 1, wherein the one or more memory devices are further configured to store instructions thereon that, when executed by the one or more processors, cause the one or more processors to:

generating a three-dimensional heat map based on the first temperature information and the second temperature information, and

providing energy to the heating system based on the three-dimensional heat map.

14. The diesel exhaust fluid system of claim 1, wherein the one or more memory devices are further configured to store instructions thereon that, when executed by the one or more processors, cause the one or more processors to:

comparing the first temperature with the second temperature;

comparing the first temperature to a predetermined threshold;

comparing the second temperature to the predetermined threshold; and

providing energy to the heating system in the following cases:

the first temperature is less than or equal to the second temperature, and the first temperature is less than or equal to the predetermined threshold, or

The second temperature is less than or equal to the predetermined threshold.

15. The diesel exhaust fluid system of claim 14, wherein the one or more memory devices are further configured to store instructions thereon that, when executed by the one or more processors, cause the one or more processors to:

if the second temperature is greater than the predetermined threshold, a signal is sent that allows operation of the diesel exhaust fluid pump.

16. A diesel exhaust fluid tank control system for a diesel exhaust fluid tank including a temperature ultrasonic liquid level and concentration (TULC) sensor and a heating system, the diesel exhaust fluid tank control system comprising:

a temperature sensor array located within the diesel exhaust fluid tank and configured to provide temperature information; and

one or more processing circuits including one or more memory devices coupled to one or more processors, the one or more memory devices configured to store instructions thereon that, when executed by the one or more processors, cause the one or more processors to provide energy to the heating system based on the temperature information.

17. The diesel exhaust fluid tank control system of claim 16, wherein the one or more memory devices are further configured to store instructions thereon that, when executed by the one or more processors, cause the one or more processors to:

determining a secondary temperature based on the temperature information received from the temperature sensor array; and

if the secondary temperature is greater than a predetermined threshold, a signal is sent that allows operation of the diesel exhaust fluid pump.

18. The diesel exhaust fluid tank control system of claim 16, wherein the one or more memory devices are further configured to store instructions thereon that, when executed by the one or more processors, cause the one or more processors to:

receiving TULC temperature information from the TULC sensor, the TULC temperature information being indicative of the TULC temperature;

determining a secondary temperature based on the temperature information received from the temperature sensor array;

comparing the TULC temperature to the secondary temperature;

comparing the TULC temperature to a predetermined threshold;

comparing the secondary temperature to the predetermined threshold; and

providing energy to the heating system in the following cases:

the TULC temperature is less than or equal to the secondary temperature and the TULC temperature is less than or equal to the predetermined threshold, or

The secondary temperature is less than or equal to the predetermined threshold.

19. A method, comprising:

receiving main temperature information indicating a main temperature from a first temperature sensor located within a diesel exhaust fluid tank;

receiving secondary temperature information indicative of a secondary temperature from a temperature sensor array located within the diesel exhaust fluid tank; and

a heating system located within the diesel exhaust fluid tank is selectively energized based on the primary temperature and the secondary temperature.

20. The method of claim 19, further comprising:

comparing the primary temperature with the secondary temperature;

comparing the primary temperature to a predetermined threshold;

comparing the secondary temperature to the predetermined threshold; and

providing energy to the heating system in the following cases:

the primary temperature is less than or equal to the secondary temperature and the primary temperature is less than or equal to the predetermined threshold, or

The secondary temperature is less than or equal to the predetermined threshold.